Method of building walls



Jan. 19, 1932. N. GARRETT METHOD OF BUILDING WALLS Original Filed Dec. 1,8, 1926 2 Sheets-Sheet 1 Jan. 19, 1932.

N. G ARRETT METHOD OF BUILDING WALLS 2 Sheets-Sheet 2 Original Filed Deo.

Patented dans 19, 'i932 NESL GRRETT, @F GILENDLE, CA'LEGRNEA.

MTHOD 0F BUILDING- WALLS Original application filed December 18, 1926, Serial No. 155,699. Bivided and this application led.

September 5, 1981.

My invention relates to building walls and is a division of my applicationSerial No. 155,699, filed Dec. 18, 1926. This application includes subject matter claimed in my applications Serial No. 170,377, filed Feb. 23, 1927, and Serial No. 257,357, led Feb. 27, 1928.

The purpose of my invention is to provide a method for making Walls of relatively thin layers of {ire-prooi` materials integrally joined together to form walls which are substantial and yet very light so as to cause relatively' small dead load stress in buildings andrelatively small impact stress in buildings due to earthquake shocks.

An object of my invention is to provide a method for building walls characterized by spaced, relatively thin, cementitious slabs, and in which the conventional frame members such as studs are eliminated by the use of light slab connecting members and light transversely extending portions of cementitious material integrally j oining and bracing the slabs.

In the drawings Figure 1 is a view showing in top plan one form of wall building apparatus embodying my invention;

Figure 2 is a fragmentary horizontal sectional view showing one rform of building wall embodying my invention;

Figure 3 is a vertical section-al view taken on the line 3-3 of Figure 1;

Figure 4 is a vertical sectional view taken on the line 4-4 of Figure 2;

Figure 5 is a fragmentary detail perspective view sho-wing one of the forms embocied in the apparatus shown in Figures 1 an 3;

Figure 6 is a fragmentary detail perspective view of one of the alining members embodied in the apparatus;

Figure 7 is -a view similar to Figure 2,

j 'showing another form of wall embodying my invention;

Figure 8 is a view similar to Figure 7, showing a third form of wall embodying my invention;

Figure 9 is a vertical sectional view taken on the line 9 9 of Figure 8.

Referring speciicallyto the drawings, and

Serial No. 561,395.

holes in which is received the upper ends of pegs 18 secured within the strip 16. In this manner the forms are held upon the base and in edge to edge relation as illustrated in Figure 1 to produce two form walls disposed in spaced parallel relation. The forms 17 are placed upon the base so as to provide intervening gaps between the vertical edges of any two adjacent forms, with the vertical edges beveled as indicated at 19 for a purpose to be described hereinafter.

To maintain the upper edges of the forms 17 in proper spaced relation and in longitudinal alinement so as to eiectively cooperate A with the base pegs 18 in rigidly holding the forms in parallel spaced relation, I construct the upper edges of the forms with up standing flanges 20 olset with respect to the inner faces of' the forms to provide' ledges on which alining members 21 are seated. The alining members may be formed of wood of any suitable length, preferably of such length as to span a plurality of forms in the manner illustrated in Figure 1. These mem- 'bers 21 are rigidly and detachably secured to the forms and to each other by means of pins 22 extended through openings 23 in the members and registering openings 24 in the flanges 20. Nailsor other suitable fastenin members 25 are extended vertically throng the members 21 and the pins 22 as illustrated in Figure 3, for the purpose of locking the members to the pins and to'thereby maintain the members contiguous to the flanges 20, whereby the upper edges of the forms 17 will be rigidly held in longitudinal alinement and in proper spaced relation to the other series of forms.

I provide between the vertical edges of adthe forms. The irregular and elastic properl the drawings.

ties of most types of reinforcing is such that even though cords 27 are tight, the average spacing of the reinforcing elements 26 from the form 17 will be substantially as shown in Cords 27 may also be considered as connecting members.

In carrying out my method, cementitious material is plastered against the outer faces of the forms 17 and over the reinforcing elelments 26 so that when the material has set such elements will be embedded therein to thoroughly reinforce the resultant wall. The cementitious material is applied laterally in such manner as to form an even coat over the outer faces of theforms, the material at the gaps between the forms, because of the be-v- I eled edges 19, producing truncated projections 30 (Figure 2), which are coextensive in height with the walls and in which the vertical edges of the webbing strips 28 are embedded. After the cementitious material has been allowed to set and sufficiently harden, `the apparatus can be removed from the wall by first withdrawing the nails 25 to allow the removal of the pins 22, and then removing the 'allining members 21. With the latter removed it will be clear that the several forms 17 can be lifted from between the confronting sides of the wall. The resultant structure thus formed is a double wall, the two 'parts of which are indicated at 31 and 32 in Figures 2 and 4 and a continuous dead air space therebetween.

` By forming openings at different intervals in the pins 22, varying the width of the base strip 16, and setting the pins 18 the desired distance apart, the apparatus can be adjusted to form a wall of any desired thickness. A wallj of any height or length may be made by discontinuing the plastering operation where desired.

Many different materials may be used as tie members in place of the webbings 28. For example, a stud 33 may be inserted in each gap between the forms in' place of the webbing 28, and the .reinforcing elements 26 nailed upon the studding so that in the complete wall the studs will appear as illustrated in Figures 8 and 9. In this adaptation the studding may be used to assist in holding and alining the forms. It is obvious that the studding may be erected and reinforcing placed over them and the forms subsequently inserted, this being an obvious variation of my invention.

It is sometimes desirable to embed the slab connecting members in cementitious material or to use instead of the type of webbings 28, transversely extending portions of cementitious material. When it is desired to do this, the cementitious material may be forced through the gaps between the forms and from the outer sides of the forms until the material from one side meets that of the other, thus forming a webbing of cementitious material, as shown in Figure 7. If the webbings 28 are used with this variation o my method they provide reinforcing for the transversely extending portions of cementitious material. It is to be understood that there are other methods of procedure by which transversely extending reinforcing may be embedded in plastered material. The method here set forth is particularly adapted for the formation of narrow walls and partitions because in this case it is easy to force the portions of the cementitious material from one side of the forms into contact with that applied to the other side of the forms.

Reinforcing 26 is preferably foraminous sheet material, such as wire mesh or expanded metal of a type adapted to reinforce layers of plastered material.

The vertical ridges formed on the backs of the slabs provide sufficient bracing for the slabs so that a wall may be made without the use of the slab connecting members. Such a wall is more sound proof and to be desired for some cases where the added strength derived by bracing the slabs together is not necessary. To build a single slab according to my invention it is only necessary to eliminate the operations incident to building one of the slabs.

In constructing my wall I leave in place only materials that were heretofore used for making nonsupporting plastered coatings.

I am the rst to use plastered slabs as reliable or forming the brace members for the slabs as they are plastered and causing the slabs and the slab connecting members or the brace members to form a structure that takes the Aplace of-the conventional type of construction.

It is considered impossible to form by the pouring method, at one continuous operation, a structure having the proportions of a structure that can be formed at one continuous operation by the method herein described. Poured slabs contain air bubbles and water pockets which are not to be found in slabs formed by trowelling cementitious material against vertical form faces. Plastered slabs arel generally formed by a plurality of laterally applied layers in which a richer film of cementitious materialisbrought to the surface of each layer, thereby producing slabs much less brittle and more resistant to shocks than in a wall formed by the pour-l ing method.

The term cementitious material is used to refer to any material in a soft state which is capable of hardening, or to any material which was at one time in a soft state and has hardened.

While I have described preferred forms of my invention, it is to be understood that the drawings and the description thereof are t0 be considered as illustrative of, rather than limitative upon, the broader claims' because it will be apparent to those skilled in the art that changes in method may be made without departing from the scope of my 1nvention.

l claim:

1. A method of making walls characterized by two spaced cementitious slabs that includes erecting foraminous sheet materials in place to reinforce the slabs and to join the slabs at spaced intervals, and plastering cementitious material over said foraminous sheet materials to form two spaced slabs and transversely extending portions of plastered material oining the slabs at spaced intervals.

2. A method of making walls characterized by spaced cementitious slabs that includes erecting two spaced vertical sheets of slab reinforcing; providing a form between said sheets of slab reinforcing, said form having openings extending therethrough transversely with respect to said sheets of slab reinforcing; Plastering cementitious material against the exterior faces of the sheets of slab reinforcing to form spaced wall slabs; protruding portions of the cementitious material through the reinforcing and into said openings from each side of the form until the protruded portions of cementitious material from one slab contact the protruded portions (5f cementitious material from the other slab to form inwardly extending-portions of plastered material joining the slabs at spaced intervals; and removing the forms.

NEAL GARRETT. 

